BOC Plasma 40 Torch User manual

Plasma 40 Torch
Operating manual

Important Notice
This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’),
as operating instructions and has been prepared in good faith. Information in this
document has been derived from third parties, and though BOC believes it to be
reliable as at the time of printing, BOC makes no representation or warranty as
to the accuracy, reliability or completeness of information in this document and
does not assume any responsibility for updating any information or correcting
any error or omission which may become apparent after the document has been
issued. The information in this document is commercial in confidence and is not
to be reproduced. The recipient acknowledges and agrees that it must make
its own independent investigation and should consider seeking appropriate
professional advice in reviewing the information. This document does not take
into account the particular circumstances of the recipient. Except insofar as
liability under any statute cannot be excluded, BOC and its affiliates, directors,
employees, contractors and consultants do not accept any liability (whether
arising in contract, tort or otherwise) for any error or omission in this document
or for any resulting loss or damage (whether direct, indirect, consequential
or otherwise) suffered by the recipient of this document or any other person
relying on the information contained herein. The recipient agrees that it shall not
seek to sue or hold BOC or their respective agents liable in any such respect for
the provision of this document or any other information.
Important Notice
This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’), as general information and does not contain and is not to be taken as containing any specific recommendation. The document has been prepared in good faith and is
professional opinion only. Information in this document has been derived from third parties, and though BOC believes it to be reliable as at the time of printing, BOC makes no representation or warranty as to the accuracy, reliability or completeness of
information in this document and does not assume any responsibility for updating any information or correcting any error or omission which may become apparent after the document has been issued. Neither BOC nor any of its agents has independently
verified the accuracy of the information contained in this document. The information in this document is commercial in confidence and is not to be reproduced. The recipient acknowledges and agrees that it must make its own independent investigation
and should consider seeking appropriate professional recommendation in reviewing and evaluating the information. This document does not take into account the particular circumstances of the recipient and the recipient should not rely on this document
in making any decisions, including but not limited to business, safety or other operations decisions. Except insofar as liability under any statute cannot be excluded, BOC and its affiliates, directors, employees, contractors and consultants do not accept any
liability (whether arising in contract, tort or otherwise) for any error or omission in this document or for any resulting loss or damage (whether direct, indirect, consequential or otherwise) suffered by the recipient of this document or any other person
relying on the information contained herein. The recipient agrees that it shall not seek to sue or hold BOC or their respective agents liable in any such respect for the provision of this document or any other information.
2BOC Smoothcut Plasma 40 Torch Operating manual

Contents.
1.0 Description 4
2.0 Torch breakdown and cutting consumables 5
3.0 Torch Ratings 6
4.0 Torch assembly 7
4.1 Fitting the consumables 7
4.2 Fitting the torch to the power source 7
4.3 Selecting the correct air pressure and flow rate 7
5.0 Cutting Technique 8
5.1 Cutting 8
5.2 Piercing and Gouging 9
6.0 Warranty 10
7.0 Safety Guidelines 11
3BOC Smoothcut Plasma 40 Torch Operating manual

The Smoothcut Plasma 40 torch is designed for plasma cutting
applications up to 40amps.
The torch requires air pressure of 5 bar for optimum operation. It has
been designed for quality cutting up to 9mm in thickness (mild steel).
The Smoothcut Plasma 40 torch has a 6m torch lead length, making it
suitable to reach even the most difficult places.
It is recommended to use the BOC Smoothcut Plasma 40 machine with
this torch to form one of the most portable cutting units on the market.
1.0 Description
4BOC Smoothcut Plasma 40 Torch Operating manual

2.0 Torch breakdown and cutting consumables
Torch breakdown and cutting consumables
Description Part No.
Smoothcut Plasma 40 Torch 6m BOC40/706HTC
1Electrode BOC9/6506
2Gas distributor BOC9/6507
3Cutting tip 20-40A BOC9/6500
4Shield cup BOC9/6003
Accessories
Description Part No.
Complete cutting guide BOC–CP1011
Roller cutting guide BOC–TJ1511
Circle cutting guide BOC–TJ1093
Spares
Description Part No.
Torch head assembly BOC9/7000
Handle & trigger assembly BOC9/7002
2
3
4
1
5BOC Smoothcut Plasma 40 Torch Operating manual

3.0 Torch Ratings
Torch Ratings
Ambient temperature 40°C
Duty Cycle 60% @ 40A
Maximum current 40A
Cooling requirement Air or Nitrogen
Gas type Air or Nitrogen
CAUTION Never use Oxygen
Gas/air operating pressure 4.8–5.0 bar
Gas/air flowrate 100 L/min
6BOC Smoothcut Plasma 40 Torch Operating manual

4.0 Torch assembly
2
3
4
1
7BOC Smoothcut Plasma 40 Torch Operating manual
4.1 Fitting the consumables
1 Place the electrode 1 into the torch head
2 Place the gas distributor 2 over the electrode
3 Place the tip 3 onto the gas distributor
4 Screw the shield cup 4 over the parts and hand tighten onto the torch
head. Do not over tighten the shield cup
IMPORTANT
As a safety feature of the torch, the cutting torch will not operate
unless the shield cup is fitted properly.
NOTE
The Smoothcut Plasma 40 torch is a contact start torch. Therefore the
cutting tip must be in contact with the work piece before the torch
switch is operated.
The contact start mechanism means that stand-off guides cannot be
used with the Smoothcut Plasma 40 torch.
4.2 Fitting the torch to the power source
1 Fit torch connection A to connection point on machine indicated as
. Screw torch connection in firmly but do not overtighten.
2 Fit the work return lead and clamp to the terminal indicated as
.
4.3 Selecting the correct air
pressure and flow rate
Compressed air from compressed air lines is often contaminated with
moisture and oil residue. Contaminants such as these shorten the life of
the consumable torch parts. It is therefore recommended that an inline
filter drying system be fitted to all air delivery lines.
When air is supplied from a portable air compressor, it is important to
ensure that the compressor has adequate pressure and airflow rate
capacity such as the BOC 14 (and upwards) air compressors.
Air supply requirements for BOC Smoothcut Plasma 40 Torch
Pressure 4.8–5.0 bar
Draw-off rate 100 L/min
A

5.0 Cutting Technique
8BOC Smoothcut Plasma 40 Torch Operating manual
Diagram 1
5.1 Cutting
As a general rule for cutting amperages below 40A the cutting tip can
be dragged on the cutting surface. Higher amperages require a stand-
off distance and torch manufacturers normally supply a stand-off guide
or ‘drag shield’. Some operators prefer to use an extended electrode
to improve visibility when cutting. BOC supplies guides that can be
purchased to assist in straight line, circular and bevel cutting.
For straight edge cutting the torch should be held at a 90° angle to the
plate and dragged along the plate (Refer to Diagram 1). The cutting
speed will depend on the material thickness, amperage and airflow rate.
For bevel cutting the torch should be angled on the plate to the required
bevel angle and dragged on the plate surface. (Note that the bevel angle
will influence the material thickness).
Typical Plasma Cutting Guide Kit
90°
Cutting Direction

9BOC Smoothcut Plasma 40 Torch Operating manual
5.2 Piercing and Gouging
To pierce material the cutting torch should be held at an angle of 45°
to the pierce surface (Refer to Diagram 2). Once the arc is established
the torch is turned to 90° (Refer to Diagram 3) and cutting is carried out
in a normal manner. Piercing thickness is dependent on the output of
the machine and is generally 50% of the rated cutting thickness of the
power source.
It is important to direct the arc away from the operator when establishing
the arc as sparks and molten material will be ejected from the point
of contact. Care must also be taken to protect the surrounds from
these sparks.
When gouging with plasma it is advisable to use a plasma gouging tip
supplied by the torch manufacturer. The torch should be held at an angle
of 40–45° from the plate surface (Refer to diagram 4). An arc length of
up to 15mm can be employed whilst the torch is moved in the direction
of the material to be removed. Several small passes should be made to
remove the unwanted material.
Diagram 3
Diagram 4
Diagram 2
90°
45°
Gouging Direction
40–45°

6.0 Warranty
The BOC Smoothcut Plasma torch carries a 12 month warranty from the
date of purchase.
This warranty excludes any consumables and apparent misuse of
the torch.
10 BOC Smoothcut Plasma 40 Torch Operating manual

7.0 Safety Guidelines
Diagram and safety explanation
Cutting sparks can cause explosion or fire.
Keep flammable materials away from cutting. Do not cut
near flammable materials.
Cutting sparks can cause fires. Have a fire extinguisher
nearby, and have a watchperson ready to use it.
Do not cut on drums or any closed container.
The plasma arc can cause injury and burns.
Turn off power before disassembling torch.
Do not grip material near cutting path.
Wear complete body protection.
Electric shock from torch or wiring can kill.
Wear dry insulating gloves. Do not wear wet or damaged
gloves.
Protect yourself from electric shock by insulating yourself
from work and ground.
Disconnect input plug or power before working on machine.
Breathing cutting fumes can be hazardous to your health.
Keep your head out of fumes.
Use forced ventilation or local exhaust to remove fumes
Use ventilating fan to remove fumes.
Arc rays can burn eyes and injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding helmet
with correct shade of filter.
Wear complete body protection.
Become trained and read the
instructions before working on the
machine or cutting.
Do not remove or paint over (cover) the label.
11BOC Smoothcut Plasma 40 Torch Operating manual

MP12-0064 . FDAUS . 1214
© BOC Limited 2014. BOC is a trading name of BOC Limited, a Member of The Linde Group. Reproduction without permission is strictly prohibited. Details given in this document are believed
to be correct at the time of printing. Whilst proper care has been taken in the preparation, no liability for injury or damage resulting from its improper use can be accepted.
BOC Limited
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970–988 Great South Road, Penrose, Auckland, New Zealand
For more information contact the BOC Customer Service Centre.
BOC Australia
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www.boc.com.au
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